Method of forming shaped laminates



Jan. 2, 1968 c. J. HANNES 3,361,610

METHOD OF FORMING SHAPED LAMINATES Original Filed May 2, 1960 2Sheets-Sheet 1 3 INVENTOR.

37V GEORGE J Hmnas Jan. 2, 1968 G. J. HANNES METHOD OF FORMING SHAPEDLAMINATES 2 Sheets-Sheet 2 Original Filed May 2, 1960 W w R t O f.-

United States Patent METHOD OF FORMING SHAPED LAMINATES George J.Hannes, Maumee, Ohio, assignor to Johns-Manville Corporation, New York,N.Y., a corporation of New York Continuation of application Ser. No.26,209, May 2, 1960.

This application Oct. 20, 1965, Ser. No. 506,422

11 Claims. (Cl. 156-219) This application is a continuation of myapplication Ser. No. 26,209, filed May 2, 1960, now abandoned, which inturn is a continuation-in-part of Ser. No. 749,165, filed July 17, 1958,now abandoned.

The present invention relates generally to fiber laminates, and moreparticularly to an improved process for forming a laminate comprising abonded body of fibers having a sheet of thermoplastic material adheredthereto.

Shaped bonded fiber structures having a thermoplastic covering layersuch as one of the vinyl resins are increasingly being used forstructures such as automobile headliners, crash pads, trim panels forvehicles, etc. Usually the thermoplastic sheet is provided with anembossed decorative design. One manner of forming such structures hasbeen to glue or otherwise secure an embossed sheet of polyvinyl resin toa mat of glass fibers bonded one to another by a cured thermosettingresin. Thermosetting resins are preferably used for the mat because ofthe relatively low cost and also because the mat need not be cooledafter being heated to activate the resin binder. This, however, is notan entirely economical process since the mat of glass fibers must firstbe formed in the usual fashion and the fibers bonded one to another toprovide a body of the desired shape. In an entirely separate operationthe embossed layer of vinyl resin is then secured to the body of fibers.

It has been proposed to apply the embossed vinyl sheet to the mat orlayer of resin impregnated fibers prior to the curing of the resin andthus cure the mat and bond the vinyl sheet thereto in a single operationwhich, of course, would be less costly. The difiiculty with this methodis that the temperature used to cure the resin must be maintained at arelatively low value, usually less than 150 R, which is insufiicient tosoften the embossed vinyl sheet, otherwise the embossed design would bedestroyed. The necessity of maintaining the curing temperature of theresin binder at such a low value increases the cost of the operationsince considerably more time is required than is the case when the usualresin curing temperatures of 250 to 350 F. can be maintained.

The foregoing difliculties may be solved by manufacturing the laminatein accordance with the method disclosed in my application, Ser. No.749,140, filed July 17, 1958, now abandoned. As there disclosed, a layerof glass fiber containing uncured thermosetting resin is assembled incontact with a thermoplastic sheet having a plain surface. The laminatethus formed is then subjected to heat and pressure between a pair ofcomplementary molding members, one of which has the surface thereofengraved with a suitable pattern which is embossed on the thermoplasticsheet when softened by the heat required to cure the thermosettingresin.

Although entirely satisfactory for producing the desired articles in aneconomical fashion, this method has one drawback in that the cost ofengraving the mold members is quite substantial. Furthermore, when it isdesired to change the surface design of the thermoplastic sheet it isnecessary to either rework the surface of the engraved mold member orelse have additional molding members maving difierent contours in stock.

It is, therefore, an important object of the present invention toprovide an efllcient and economical method of forming a laminatecomprising a layer of bonded fibers having an embossed thermoplasticsheet secured to a surface thereof.

Another object of the invention is to provide a one-step operation offorming such a laminate in which the binder for the fibers is curedwhile at the same time the thermoplastic sheet is embossed and securedto the layer of fibers.

The foregoing and other objects and advantages of the invention willbecome apparent in the course of the following description.

In the drawings, wherein like numerals are employed to designate likeparts throughout the same:

FIG. 1 illustrates a sandwich structure showing the various layers whichgo to form a unitary laminate positioned with reference to a texturingor embossing member for imparting the desired design to thethermoplastic sheet;

FIG. 2 illustrates a fragmentary section of one type of laminate formedin accordance with the invention;

FIG. 3 diagrammatically illustrates the molding apparatus used to carryout the method of this invention in open position;

FIG. 4 diagrammatically illustrates the molding apparatus in a closedposition and shows a glass fiber resin impregnated laminate structurebeing cured under heat and pressure;

FIG. 5 is a sectional plan view taken along the line 5-5 of FIG. 3; and

FIG. 6 is a sectional elevation view of a modified type of moldingapparatus.

The method of the present invention comprises placing in contact withone another one or more fibrous layers containing an uncuredthermosetting binder and a continuous layer or sheet of thermoplasticmaterial preferably of the vinyl type. Against the surface of the vinyllayer opposite that contacted by the fibrous mat an embossing member ortextured surface is placed which has the surface thereof provided withthe desired configuration to be imparted to the thermoplastic sheet.

The assemblage of fibrous layer, or layers, thermoplastic sheet andembossing or texturing member is then simultaneously subjected topressure and heat sufi'icient to cure the thermosetting resin.Generally, a temperature of between about 290 F. to 370 F. and for atime interval of two to three minutes is sufiicient. At thesetemperatures the thermoplastic sheet readily softens, and due to thepressure has the surface contour or configuration of the embossingmember imparted thereto. The pressure applied will depend upon thedegree to which the fibrous mat is to be compressed and will vary tothis extent. After the resin is cured the heat and pressure isdiscontinued and the embossing member separated from the laminate whichis then ready for use.

With reference now to the drawings there is shown in FIG. 1 a pair ofglass fiber mats 9 and 10 and a thermoplastic sheet 11 which go to makeup a sandwich structure or laminate 12 which is to be positioned incontact with a textured or embossing member 13 which has the surface 14thereof, which is to be contacted by the laminate, engraved with adesired design to be imparted to the thermoplastic sheet. The member 13may be a fabric woven to a desired design, a metal plate having anengraved surface, or any type of member having other than a smoothsurface which does not lose its surface configuration at a temperatureabove the softening temperature of the thermoplastic sheet andpreferably at a temperature up to about 400 F.

The glass fiber mats 9 and 10 each may have an uncured thermosettingresin applied thereto or the mat 10, which is to be contacted by thethermoplastic sheet 11, may be impregnated with an uncured thermosettingresin while the mat 9 has the fibers thereof bonded one to another by a.cured resin. Prior to assembling the fiber mats and the thermoplasticsheet in contact one with another a film or coating of a heat curableadhesive is preferably applied to the surface of the sheet 11 facing themat 10 so as to better bond the sheet to the mat. A vinyl or acrylicemulsion type adhesive is suitable for this purpose. This is notnecessary, however, if the resin is applied to the fibrous mat in anamount sufficient to bind the mat to the thermoplastic sheet.

It will be understood, of course, that only one layer of fiberscontaining unactivated thermosetting resin need be used for the laminate12. In general, however, it is desirable in order to obtain adequatethickness of the laminate to employ a plurality of mats having anuncured resin contained therein, or one layer having a cured resin andthus dimensionally stable in thickness and one or more layers having anuncured resin contained therein which, during the curing process, arecompressed to a materially greater density than the layer having thecured resin thus providing a structurally stronger skin having a hardsurface to which the thermoplastic sheet is bonded.

The laminate formed in accordance with the procedure previously setforth is placed in contact with the textured member 13 and theassemblage thus formed is then subjected to heat and pressure for a timesufi icient simultaneously to cure the resin binder, bond the laminatelayers one to another, and soften the thermoplastic sheet so that thesurface design of the textured member 13 is embossed on sheet 11.Various means may be used to apply the heat and pressure; for example,the sandwich may be placed between metal plates and then passed througha roller type furnace. If a method of this type is employed sufficientweight should be added to the upper sheet so as to produce a pressurecalculated to give the desired density of the layer of fibers having theuncured resin applied thereto.

A platen type press 15 shown in FIGS. 3 to 5 may be used when it isdesired to form curved structures. The press 15 comprises an upperplaten 16 and a lower platen 17, the upper platen being fixedly securedto vertical support members 18 and 19 and the lower platen 17 beingslidably mounted on said supporting members. Vertical movement of thelower platen 17 toward and away from the upper platen is adjustablycontrolled by a hydraulic cylinder 20. Electrical heating elements 21,which are thermostatically controlled, are positioned within the upperand lower platens directly beneath the molding surfaces 22 and 23respectively thereof to supply heat to each of the platens.

The marginal portion of the upper surface of the lower platen 17 isprovided with an outwardly extending flat ledge 24 which has itsperiphery terminating at a continuous hollow chamber 25, having itsupper surface 26, which is at a level slightly above the ledge 24,provided with a plurality of spaced openings 27 positioned around .theperiphery of the surface 26 and, by the chamber 25,

connected by means of a conduit 28 to a source of vacuum (not shown).

With'a platen apparatus of this type a rigid curved textured orembossing member 13 of the typeshown in FIG. 1 may be used. The member13 has sufficient rigidity 4 metal sheet, is spaced inwardly from theopenings 27 so that vacuum may be applied to the undersurface of thesheet 11.

In forming a laminate such as shown in FIG. 2 with the apparatusillustrated in FIGS. 3, 4, and 5, and in accordance with the method ofthe invention, the lower platen 17 is initially heated to a temperaturebetween 200 F. and 400 F. while the upper platen 16 is initially heatedto a temperature between 300 F. and 500 F. The heat conductive embossingplate 13 is then placed upon the upper surface 23 of the lower platenand the sandwich structure or laminate 12 is then placed in the moldupon the embossing plate with the sheet 11 over the openings 27.Alternatively, the laminate 12 may be'assembled upon the member 13 andthe assemblage thus formed placed upon the platen 17. Also, ifldesired,the platens may be heated after the laminate is in position. In anyevent, it is desirable to heat the lower platen to a temperature lowerthan that to which the upper platen is heated so as to heat thethermoplastic sheet to a lower temperature than the fibrous mat so thatan extended cooling period of the sheet after laminating may be avoided.When relatively thin thermoplastic sheets are used difierential heatingis not important since thin sheets cool very rapidly and may be readilyfreed from the embossing member substantially immediately after theassemblage is removed from between the platens.

When the laminate is positioned in the mold, the peripheral margin ofthe thermoplastic sheet 11, which has a greater area than the member 13,will overlie the lip 29 p of the member 13 and rest upon the uppersurface 26 of the evacuating chamber 25. A vacuum is then applied to thechamber 25 and acts through the openings 27 to tightly retain themargins of the thermoplastic sheet 11 in position relative to theembossing member 13 and cause atmospheric pressure to press the sheetinto intimate contact with the member 13. The lower platen is thenraised to compress the laminate between the upper and lower platensunder a pressure of approximately pounds per square inch.

A curing cycle of approximately two minutes at 'an average upper andlower platen temperature of between 290 F. to 350 F. and preferablyabout 300 F. is ordinarily preferred to bond the laminate completelythroughout. At the end of the curing cycle, the lower platen 17 islowered and the textured or embossing member 13 and the cured laminatesupported thereon are then removed as a unit from the molding apparatusand preferably allowed to cool before the laminate is stripped from theembossing member. The amount of time necessary for the laminate to coolin contact with the member 13 will depend on the thickness of thethermoplastic sheet 11. For thin sheets in the order of 6 to 12 mils thelaminate 12 need not be removed on the member 13, but may be liftedvertically therefrom thus preventing sliding contact which could mar thesurface of the still hot thermoplastic sheet. For thicker sheets thetime increases in proportion to the thickness, but in general about oneminute is sufficient. Byremoving the laminate while supported upon themember 13, greater production rates may be obtained since it is notnecessary to either" cool the platens or the assemblage until thethermoplastic sheet has cooled below its softening point.

It was previously brought out that molding members having engravedsurfaces could be used in forming a laminate having an embossed surface.The present method is an improvement over the use of engraved moldingmembers in that the surface design of the laminate may be changed bysimply using an embossing or texturing member havingva different surfacecontour. Also, when relatively thick thermoplastic sheets are used acured laminate may immediately-be' removed upon its embossing member andcooled while a second laminate andernboss'ing member are positionedbetwenthe platens, thu providing for increased production rates.

When each of the fibrous mats 9 and 10 contain an uncured thermosettingresin, the resin during the heating and pressing step flows to a certainextent between the mats and also into contact with the thermoplasticlayer or sheet 11 thus providing a firm bond between the several layersforming the laminate. Also, as previously pointed out, an adhesive maybe used between layers 10 and 11 to bond the thermoplastic sheet to theadjacent fibrous layer.

To provide a laminate having a dense, hard skin to which thethermoplastic sheet is secured and a relatively soft body portion, layer10 should contain an uncured resin binder, layer 9 should have thefibers thereof bonded one to another, and a small amount of additionalbinder is preferably added to the interfaces of layers 9, 10 and 11.While such a laminate is being cured, the mat 10 is compressed to arelatively thin layer having a density four or five times that of mat 9.Also, the resin contained in the mat 10, during the heating thereof,bonds the fibers of said layer one to another so that the layer takes onthe curvature of the upper and lower platens. Due to the compression andheating of the mat 10, a certain portion of the resin contained thereinflows to the interfaces between mat 10 and mat 9 and sheet 11 and forms,upon curing, a firm bond between the three layers or plies of thelaminate. The upper mat 9, the fibers of which were originally bondedtogether by the cured thermosetting resin, resumes its originalthickness upon removal from the mold while the more rigid mat 10, havingthe fibers thereof bonded one to another while the layer is curved, iscured to the contour of the platen and because of its rigidity holds thelayer 9 in the same curved shape. Laminates of such construction aredesirable in many instances because of the rigidity provided by thelayer 10.

In FIG. 6 there is shown apparatus 30 for carrying out a modified formof the method of the invention. The apparatus 30 comprises upper andlower platens 31 and 32 which are supported by a structure (not shown)identical to that used for supporting and activating the platen pressshown in FIGS. 3 and 4. The platens 31 and 32 may be heated similarly tothe platens 16 and 17 by means of electrical heating elements 33, andeach has its molding surface 34 and 35, respectively, curved to thedesired curvature to be imparted to the laminate. The

apparatus differs from the press 15 in that the surface 4 35 of thelower platen terminates at the periphery thereof in an encircling,upstanding wall 35 provided along its base with a series of openings 37to which a vacuum may be applied by suitable means (not shown).

The textured or embossing member utilized with the modified method ofthe invention is preferably flexible and formed of a material which isinert at temperatures up to about 400 F. Fabrics formed of mineralfibers are satisfactory for this purpose, and very satisfactory texturedmembers have been formed of glass fibers woven into a cloth having thedesired decorative pattern to be imparted to the surface of thethermoplastic sheet 11. Preferably, the weave or construction of thetextured member is such as to provide a foraminous sheet which is airpervious so that, as will be later explained, vacuum may be applied toall portions of the under surface of the thermoplastic sheet thuscausing the same to more intimately contact the textured member.

In carrying out the modified method of the invention, a textured orembossing member 38, formed of a layer of air .pervious, flexible wovenglass cloth, is placed on the upper surface 35 of the lower platen 32and is of such an area as to cover substantially completely the surface35. A thermoplastic sheet 39 having an area greater than that enclosedby the wall 36 is stretched over the wall and placed in tension by meansof a ring 40 which is clamped to the periphery thereof. One or morelayers or mats of glass fibers 41 having an inactivated thermosettingbinder are then placed upon the upper surface of the thermoplastic sheetafter which a vacuum is applied to the openings 37 to evacuate the areaabove the mold surface 35 and beneath the sheet 39 which causes theatmosphere to press evenly upon all portions of the laminate formed bythe glass fiber layers and the thermoplastic sheet whereby the laminateis drawn or pressed down- Wardly. Since the member 38 is foraminous thethermoplastic sheet 39 is drawn into intimate contact therewith due tothe fact that the vacuum is applied to substantially the entire area ofthe undersurface of the sheet 39.

After the laminate has been drawn into contact with the lower platen 32,the platen is raised upwardly as was the case with the mechanism ofFIGS. 3 and 4 and the laminate is cured at a temperature between about250 F. to 350 F. and for between about two to four minutes. Preferably,the cure temperature is about 300 F. and for a time interval of aboutthree minutes. The lower platen is then moved downwardly and theassemblage comprising the laminate and the textured member is thenlifted from the lower platen and cooled for a short time interval priorto stripping the textured member from the surface of the thermoplasticsheet. Usually one or two minutes at room temperature is sufficient forthe thermoplastic sheet to cool to the extent that the surface patternis not marred when the textured sheet is stripped therefrom. In general,it is only necessary to allow the thermoplastic sheet to cool below thetemperature at which the pattern could be marred by removing theembossing member. Usually, cooling the sheet to a temperature less thanabout F. is satisfactory.

If desired, an alternate procedure may be used in which the laminate isstripped from the textured member immediately after the platens haveopened. In this case the textured member 38 is secured to the uppersurface 35 of the lower platen by a suitable adhesive and forms asemi-permanent member upon which a number of laminates may be formed.When removing the laminate from a textured member so secured, care mustbe taken that the laminate is removed substantially vertically so thatthe surface pattern of the sheet is not marred. This is necessary sincethe textured member will be quite hot due to heat conducted therethroughby the lower platen, and thus relative lateral movement between the twowhile in contact with one another would mar the surface confiuration ofthe thermoplastic sheet.

The modified process of the invention utilizing the flexible texturedmember is more advantageous than the use of the substantially rigidmember 13 shown in FIG. 1 in that a metal member of this type must havethe surface thereof engraved to produce a suitable embossing of thethermoplastic sheet. This is not the case when using a fabric woven to adecorative pattern. Also, a change of curvatures is much lessexpensively accomplished with a flexible textured member since suchmember would readily conform to differently curved platens. Furthermore,a better positive contact of the thermoplastic sheet with the texturedmember is provided since the region beneath substantially the entireundersurface of the thermoplast-ic sheet may be evacuated.

It has been found that glass fiber mats composed of glass fiber having adiameter in the order of 2 to 6 or 7 microns and an average diameter ofapproximately 3 or 4 microns produce satisfactory mats for forminglaminate structures produced in accordance with the method of theinvention. Mats of this type may be formed in accordance with theteachings of US. Patent No. 2,489,- 242 and preferably the thermosettingresin is applied in the form of a spray as the fibers are collected intomat form. The thickness of the uncured mat may vary and is preferablybetween about /2 to 1 inch depending upon the type of shaped laminate tobe formed. The resin content of the mat may be varied between about 7%to 30% by weight of the mat. Generally, a resin content of about 20% isdesirable. Any of the normally used thermosetting resins, such as phenolformaldehyde and melamine formaldehyde condensation products may beused. If the laminate is formed using one or more initially unbondedmats, a satisfactory density for the fibers in the cured laminate is onthe order of about 2 to 6 pounds per cubic foot and may run as high as10 pounds per cubic foot. If the laminate is formed using a mat offibers bonded one to another and a second mat of fibers containing anunactivated resin, a satisfactory density for the bonded mat may runfrom between about A to 3 pounds per cubic foot, and the density of theinitially uncured mat, after laminating and depending upon the amount ofpressure used, may vary from about 3 pounds per cubic foot up to about20 pounds or more per cubic foot.

As previously pointed out, the amount of pressure to be applied duringlaminating will vary depending upon the type of structures to beproduced. In general, it has been found that pressures in the order ofabout 100 pounds per square inch are satisfactory for producing either alaminate in which a layer or layers of unbonded fibers are employed orwhen a layer of bonded and a layer of unbonded fibers are used. Thepressures may range from about 5 to 150 pounds per square inch since itis desired that a relatively compact fibrous structure is to be formedhaving high structural strength so that the laminate is capable ofspanning up to 10 feet or more without the necessity of employingintermediate supports.

Shaped structures produced in accordance with the method of the presentinvention have been found to be well suited for use as headliners ortrim panels in automobiles, wall structures and various other like uses.The fibrous layer provides a firm, compact and yet semiresilient backingfor the decorative thermoplastic layer which, because of its proven wearresistance, provides a very suitable exterior surface.

While the invention has been described in rather full detail, it will beunderstood that these details need not be strictly adhered to and thatvarious changes and modifications may suggest themselves to one skilledin the art, all falling within the scope of the invention as defined bythe subjoined claims.

What I claim is:

l. A method of forming a decorative laminate panel, comprising formingan assemblage comprising a body of low density glass fiber of at leastone layer of a mat impregnated with about 7 to about 30% by Weight ofuncured thermosetting resin, a; thermoplastic sheet having a surface incontact with the glass fiber mat containing uncured thermosetting resin,and a texture member in contact with the opposite surface of thethermoplastic sheet, simultaneously applying to the assemblage pressurebetween a pair of complementary molding platens and heat to atemperature above the softening point of the thermoplastic sheet andsufficient to cure the thermosetting resin binder, thereby substantiallysimultaneously compressing the low density glass fiber body andthermally curing the uncured thermosetting resin binder of thecompressed glass fiber mat bonding the fiber of the mat and the mat tothe thermoplastic sheet, and commensurate therewith the said appliedheat softening the thermoplastic sheet and the said applied pressureembossing the thermally softened thermoplastic sheet with the pattern ofthe textured surface, cooling the embossed thermoplastic sheet below itssoftening point to set the embossed pattern, and removing the texturedmember from the said thermoplastic sheet.

2. The method of forming a decorative laminate panel as defined in claim1, wherein an adhesive is applied to the inner face between thethermoplastic sheet and the glass fiber mat.

3. The method of forming a decorative laminate panel as defined in claim1, wherein pressure is discontinued ,during cooling.

4. The method of forming a decorative laminate panel as defined in claim3, wherein the thermoplastic sheet and textured member are retained incontact with one.

' another until the thermoplastic sheet is cooled below its thermalsoftening point.

5. The method of forming a decorative laminate panel as defined in claimwherein the textured member is substantially rigid, the pressure andheat are simultaneously applied to the assemblage while the assemblageis located between a pair of complementary pressure applying members,and the compressed assemblage is removed from between the members as aunit and then cooled to below the thermal softening point of thethermoplastic sheet.

6. The method of forming a decorative laminate panel as defined in claim1, wherein the assemblage is simultaneously compressed and heated bylocating the assemblage between opposed surfaces of a pair of platens,each of which is at a temperature above the softening point of thethermoplastic sheet.

7. The method of forming a decorative laminate panel as defined in claim6, wherein the assemblage receiving surface on one platen is curved, thetextured member is flexible and initially placed in contact with saidcurved surface of the platen, and prior to applying pressure to theassemblage, the thermoplastic sheet is pressed against the texturedmember.

8. A method of forming a decorative laminate panel, comprising formingan assemblage including a body of low density glass fiber of at leastone layer of a mat impregnated with about 7 to about 30% by weight of anuncured thermosetting resin, a thermoplastic sheet having a surface incontact with the glass fiber mat containing uncured thermosetting resin,and a textured surface in contact with the opposite surface of thethermoplastic sheet, simultaneously compressing said assemblage betweena pair of complementary molding platens and applying heat to theassemblage sufficient to raise the temperature of the assemblage to apoint higher than the softening point of the thermoplastic sheet,thereby substantially simultaneously compressing the low density glassfiber body while thermally curing the uncured thermosetting resin binderof the compressed glass fiber mat bonding the fiber of the mat andbonding the assemblage together, commensurate with the said applied heatsoftening the thermoplastic sheet and with the said applied pressureembossing the thermally softened thermoplastic sheet to theconfiguration of the textured member, and cooling the embossedthermoplastic sheet of the assemblage below its softening point to setthe embossed pattern and removing the textured sheet from the saidthermoplastic sheet, the said heating step carried out simultaneouslywith compression of the assemblage consisting of applying a highertemperature to the compressed glass fiber mat than is applied to thethermoplastic sheet.

h. The method of forming a decorative laminate panel as defined in claim8, wherein the pressure and heat is applied to the assemblage by a pairof complementary platens between which said assemblage is located, andthe platen adjacent to the glass fiber mat is heated to a temperature ofapproximately 300 to approximately 500- F. and the temperature of theplaten adjacent to the textured surface and thermoplastic sheet isheated to a temperature of approximately 200 to approximately 400 F.

10. The method of forming a decorative fibrous laminate panel,comprising forming an assemblage including a low density glass fiber matof approximately to approximately 3 pounds per cubic foot containingabout 7 to about 30% by weight of an uncured thermosetting resin, athermoplastic sheet and a flexible textured member, simultaneouslyapplying pressure between a pair of complementary molding platens andheat to the assemblage to a temperature above the softening point of thethermoplastic sheet and sufiicient to cure the thermosetting resinbinder, thereby substantially simultaneously compressing the low densityglass fiber mat to a density of approximately 3 to approximately 20pounds per cubic foot while thermally curing the uncured thermosettingresin binder of the compressed glass fiber mat, bonding the fiber of themat and bonding the assemblage, commensurately therewith the saidapplied heat softening the thermoplastic sheet and with the said appliedpressure embossing the thermally softened thermoplastic sheet to theconfiguration of the textured member and cooling the embossedthermoplastic sheet below its softening point to set the embossedpattern, and thereafter removing the said textured member from thethermoplastic sheet.

11. The method of forming a decorative fibrous laminate panel as definedin claim 10, wherein the temperatures applied to the glass fiber mat areapproximately 300 to approximately 500 F. and the temperatures appliedto mately 200 to approximately 400 F.

References Cited UNITED STATES PATENTS Loetscher.

Jenkins 156-219 Reynolds et al. 156219 Walker et a1 156219 Johnston156-219 De Ganahl et al.

Hickler.

EARL M. BERGERT, Primary Examiner. ALEXANDER WYMAN, Examiner. thetextured member thermoplastic sheet are approxi- 15 VANBALEN, SCHWARTZ,

Assistant Examiners.

1. A METHOD OF FORMING A DECORATIVE LAMINATE PANEL, COMPRISING FORMINGAN ASSEMBLAGE COMPRISING A BODY OF LOW DENSITY GLASS FIBER OF AT LEASTONE LAYER OF A MAT IMPREGNATED WITH ABOUT 7 TO ABOUT 30% BY WEIGHT OFUNCURED THERMOSETTING RESIN, A THERMOPLASTIC SHEET HAVING A SURFACE INCONTACT WITH THE GLASS FIBER MAT CONTAINING UNCURED THERMOSETTING RESIN,AND A TEXTURE MEMBER IN CONTACT WITH THE OPPOSITE SURFACE OF THETHERMOPLASTIC SHEET, SIMULTANEOUSLY APPLYING TO THE ASSEMBLAGE PRESSUREBETWEEN A PAIR OF COMPLEMENTARY MOLDING PLATENS AND HEAT TO ATEMPERATURE ABOVE THE SOFTENING POINT OF THE THERMOPLASTIC SHEET ANDSUFFICIENT TO CURE THE THERMOSETTING RESIN BINDER, THEREBY SUBSTANTIALLYSIMULTANEOUSLY COMPRESSING THE LOW DENSITY GLASS FIBER BODY ANDTHERMALLY CURING THE UNCURED THERMOSETTING RESIN BINDER OF THECOMPRESSED GLASS FIBER MAT BONDING THE FIBER OF THE MAT AND THE MAT TOTHE THERMOPLASTIC SHEET, AND COMMENSURATE THEREWITH THE SAID APPLIEDPRESSURE EMBOSSING THE THERMALLY SOFTENED THERMOPLASTIC SHEET WITH THEPATTERN OF THE TEXTURED SURFACE, COOLING THE EMBOSSED THERMOPLASTICSHEET BELOW ITS SOFTENING POINT TO SET THE EMBOSSED PATTERN, ANDREMOVING THE TEXTURED MEMBER FROM THE SAID THERMOPLASTIC SHEET.